Resistance welding circuit



Oct. 29, 1968 J. A. GILBERT RESISTANCE WELDING CIRCUIT 5 Sheets-Sheet 1 Original Filed May 25 1963 i m h 3 a m: w, i

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Oct. 29, 1968 J. A. GILBERT 3,408,473

RES I STANCE WELDING CIRCUIT Original Filed May 23, 1963 5 Sheets-Sheet 3 6.5 .62 fi' F S w /5 6? *4 I QPLZ:

5%: Z ja /A iga? United States Patent 3,408,473 RESISTANCE WELDING CIRCUIT John A. Gilbert, Upland, Calif., assignor to Unitek Corporation, Monrovia, Calif., a corporation of v California Original application May 23, 1963, Ser. No. 282,753, now Patent No. 3,317,703, dated May 2, 1967. Divided and this application Apr. 27, 1967, Ser. No. 634,162

11 Claims. (Cl. 219-111) ABSTRACT OF THE DISCLOSURE A resistance welding circuit which produces a plurality of DC pulses during each welding sequence. In addition to a welding pulse of a predetermined amplitude the circuit also provides a preheating and optionally a postheating pulse of an amplitude less than the welding pulse. The duration of each pulse is controlled by a separate oneshot multivibrator and when a given multivibrator is operated a switch is closed connecting a resistor and a DC source of energy in series with the welding electrodes. The value of each of the resistors connected in series with the DC source determines the amplitude of the pulses in each sequence.

Cross reference to related application This is a division of application Ser. No. 282,753, filed May 23, 1963, now Patent Number 3,317,703.

Background of the invention This invention provides an improved welding circuit, particularly of the type used in stop welding.

Two pieces af work are spot welded together by contacting the work with a pair of welding electrodes, and passing sufficient welding current through the electrodes and Work so that the two pieces are welded together where they contact each other due to the heating produced by the contact resistance. In this type of welding it is often important that the Welding current be carefully controlled to insure a good weld, particularly when small or delicate parts are welded together. For example, in welding microcircuits which are deposited on a glass substrate, the welding current must be carefully controlled to avoid chipping or cracking. Welding circuits prior to this invention do not provide the necessary control and fine adjustment required for many types of delicate welding operations..As a consequence, the prior art circuits often require considerable trial and error attempts which result in expensive and time-consuming setups, and there is often a substantial waste of parts to be welded.

The circuit of this invention is quickly and easily adjusted to a fine degree to provide the exact current required to weld delicate parts Without cracking or chipping.

Summary of the invention Briefly, the circuit includes a direct current source and a pair of welding electrodes. Circuit means are included for developing afirst pulse of direct current from the source. Means are provided for applying the first pulse of.

direct current to the welding electrodes. Means are also included for developing a second pulse of direct current from the source in response to the first pulse, and means are provided for applying the second pulse to the electrodes. The first pulse preheats the weld area to avoid extreme thermal shock when the second or welding pulse is applied to the electrodes. Preferably, the second or welding pulse is followed immediately by a third or postheating pulse to prevent damage to the work from too rapid cooling.

Ordinarily, the second pulse includes more power than the first, or the third, if a third is used. Conveniently, the second pulse is higher than the first or the third pulse.

Means are preferably provided for separately adjusting the width and height of each pulse. Conveniently, the pulses are generated by a series of one shot multivibrators connected in tandem so that the end of a pulse of a preceding multivibrator triggers a following multivibrator to generate an immediately following pulse.

In one presently preferred embodiment the welding electrodes are connected in series with the direct current source and the emitter and collector of a transistor. Control pulses are applied to the transistor base. to apply relatively long, low voltage pulses of welding current to the electrodes. Preheating and post-heating pulses are similarly applied.

These and other aspects of the invention will be more fully understood from the following detailed description Detailed description Referring to FIG. 1, a pair of welding electrodes 10 and 11 are connected to electrical leads 12 and 13, respectively. Two pieces of work 14 are disposed as shown in FIG. 13 to be spot welded together when a pulse of current passes through the electrodes. The welding pulse is developed when the welding electrodes are applied to the work with a predetermined amount of force, such as with the force-sensing arrangement disclosed in US. Patent 2,872,564.

When the electrodes are applied to the Work with the preset force, a start pulse switch 16 is closed to apply a positive going pulse to an input 17 of a first one shot multivibrator 18, which may be conventional and is shown only schematically in FIG. 1. A detail circuit of a one shot multivibrator is shown in FIG. 2. A supply voltage,which typically may be about -12 volts, is supplied from a conventional rectifier 20 over a line 21 to the supply input terminals 22, 23, and 24, of the first one shot multivibrator 18, and second and third one shot multivibrators 25, 26, respectively.

A driving voltage, which typically may be about 17 volts, is supplied from the rectifier through a driving voltage line 28 to the common ends of three relay coils 29, 30, and 31 of the first, second, and third relays 32, 33, and 34, respectively. The opposite ends of the first, second, and third relay windings are each separately respectively connected to the collectors 35, 36, and 37 of first, second, and third transistor switches 38, 39, and 40 respectively. Diodes 40A, 40B, and 40C are connected in parallel with the relay coils 29, 30, and 31, respectively, to eliminate inductive transients and protect transistor switches 38, 39 and 40 from burn-out due to transient voltage spikes. The emitters 41, 42, and 43 of each transistor switch are each connected directly to ground, and the bases 44, 45, and 460i the first, second, and third transistor switches are each connected to ground through a resistor or through a separate resistor 47, 48, 49, respectively.

Supply voltage line 21 is connected to a pair of seriesconnected resistors 50, 51 which act as a voltage divider. The switch 16 is connected to the common ends of the voltage divider, which in turn are connected to the input 17 of the first one shot multivibrator.

A first timing lead 52 from the first one shot multivibrator is connected across the common sides of timing capacitors 53 through 62. A second timing lead from the one shot multivibrator is connected across the opposite side of capacitor 53 and is arranged to be connected through a switch 64 to the opposite sides of capacitors 54 through 62. Switch 64 is a rotary type which progressively picks up and shorts all contacts as it is advanced down the line. This arrangement reduces the size of the capacitor required at each position. Thus, by setting switch 64 in any one of the nine available positions, the width of the pulse developed by the one shot multivibrator can be adjusted. Conveniently, the capacitors 53 through 62 are of the range to permit the pulse width of the first one shot multivibrator to be adjustable between milliseconds and 100 milliseconds.

First and second timing leads from the second and third one shot multivibrators are also connected across a bank of capacitors identical with those connected to the first one shot multivibrator so that the capacitors can be used to adjust the width of the pulses developed by the second and third one shot multivibrators. For brevity, a detailed description of the connection of the capacitors to the second and third one short multivibrators is not repeated.

When a positive going pulse is applied to the input of the first one shot multivibrator, a negative pulse is developed on the output lead 66 of the first one shot multivibrator. The width of the pulse depends upon the setting of switch 64. With the one shot multivibrator of the type shown in FIG. 2, the voltage on the output lead 66 may change from about 3 volts to about 11 volts. This output is fed through a Zener diode 68 and a resistor 70 to the base of the first transistor switch, which is turned on for a time corresponding to the width of the pulse. This pulse on the base of the first transistor switch causes it to go from normally nonconducting to full conducting so the current flows through the winding 29 of the first relay causing relay contact 72 to close and apply a pulse of voltage from a center-tapped battery 74 through a first variable attenuator resistor 76, a main variable attenuator resistor 78, and base resistors 79, 80 to the bases 81 and 82, respectively, first and second parallel-connected transistor power amplifiers 83 and 84. A biasing resistor 85 connects the two common ends of resistors 79 and 80 to ground. On receipt of the pulse through the relay contact 72, the amplifiers conduct at a level in accordance with the input pulse current level determined by the attenuators. A preheat pulse of a height depending on the setting of attenuators 76 and 78 then flows from a center-tap lead 86 of the battery through the welding electrodes, the parallel-connected transistor amplifiers, and to ground. This applies the preheating pulse to the work so it is preheated to the required temperature prior to the application of the welding pulse in response to the pulse developed by the second one shot multivibrator, whose operation will now be described.

When the first one shot multivibrator returns to its original state, the voltage on the output 66 goes from about 11 volts to 3 volts. This positive going pulse is applied to a lead 88 to the input of the second one shot multivibrator, which then develops an output pulse at its output lead 90. The width of the output pulse is determined by the setting of the control switch across the capacitors connected to the second one shot multivibrator. The pulse from the second one shot multivibrator is of any desired height and width, depending on the nature of the work being welded. A negative going pulse from the output of the second one shot multivibrator is fed through a Zener diode 92 and a resistor 93 to the base of the second transistor switch, which is then made full conducting for a time corresponding to the width of the second or welding pulse. While the second transistor switch is full conducting, current flows through the second relay winding 30 and a pair of contacts 94 in the second relay are closed so that current flows from the battery through a second variable attenuator resistor 96, the main variable attenuator resistor 78, and to the bases of the two power transistor amplifiers.

Two power transistor amplifiers conduct for the width of the second pulse, and a welding pulse of a height or amplitude depending on the setting of the second variable attenuator resistor 96 is passed through the welding electrodes and work, causing the work to be heated sufficiently to melt and fuse together. To prevent too rapid cooling of the weld and work, the circuit preferably follows the welding pulse immediately with a postheating pulse.

When the output pulse from the second one shot multivibrator is turned off, a positive going pulse is applied through a lead 98 to the input 99 of the third one shot multivibrator which is then triggered to deliver a negative pulse from its output lead 100 through a Zener diode 101 and a resistor 102 to the base of the third transistor switch, which then goes full conducting for a time corresponding to the width of the output pulse from the third one shot multivibrator. While the third transistor switch is conducting, contacts 104 in the third relay close and apply current from the battery through a third variable attenuator resistor 106, and the main variable attenuator resistor 78 to the bases of the two transistor power amplifiers. This applies a postheating pulse through the electrodes and work so that the work is cooled at the desired rate to avoid cracking or chipping.

The one shot multivibrators are shown only in schematic form in FIG. 1 because they may take any one of the well known conventional forms. They may be made up of either vacuum tubes or solid state devices such as transistors. A typical one shot multivibrator which can be used in the circuit of FIG. 1 is shown in detail in FIG. 2, and the same reference numerals are used in FIG. 2 to identify the leads which correspond to those identified by the same reference numerals in FIG. 1. Two pnp transistors 112, 114 are connected as shown in FIG. 2 through conventional rectifiers, Zener diodes, capacitors and resistors in a usual one shot multivibrator circuit. Input lead 17 is connected to the base of transistor 112, and output lead 66 is connected to the collector of transistor 112. First and second timing leads 52 and 63 are connected in a circuit as shown, and are the same leads used to connect across the bank of capacitors 53-62 shown in FIG. 1. Since the operation of the circuit shown in FIG. 2 is conventional, and forms no part of this invention, its description is not presented here in detail, for brevity.

The advantage of the welding circuit of this invention is that the preheat, welding, and postheating weld pulses are easily and finally adjusted in both width and amplitude by the capacitor switches or the variable attenuator resistors. Moreover, the pulses immediately follow each other with no pause or interval in between so that smooth and accurate control of the work temperature is easily obtained.

Typical preheat, welding, and postheating pulses produced by the circuit of FIG. 1 are shown in FIG. 3. The preheating pulse 108, welding pulse 109, and postheating pulse are developed by the outputs of the first, second, and third one shot multivibrators, respectively. It will be observed that one pulse immediately follows the other, so there is no cooling or waiting period in between pulses. Thus, with the circuit of this invention, the work can be preheated to any desired degree, the welding temperature can be adjusted to whatever is required, and the work can be cooled or postheated independently of either the preheating or the welding temperature.

What is claimed is:

1. A welding circuit comprising a direct current source, a pair of welding electrodes, a first one shot multivibrator having an input and an output, a second one shot multivibrator having an input and an output, means connecting the multivibrators to the direct current source, means connecting the output of the first multivibrator to the input of the second multivibrator and to the welding electrodes, means connecting the output of the second multivibrator to the welding electrodes, and means for actuating the first multivibrator to develop a first pulse which is applied to the welding electrodes, and which at its end actuates the second multivibrator to develop a second pulse which is applied to the welding electrodes.

2. A welding circuit according to claim 1 including a third one shot multivibrator having an input and an output, means connecting the third multivibrator to the di rect current source, means connecting the output of the second multivibrator to the input of the third multivibrator, to the welding electrodes, and means for actuating the third multivibrator responsive to the actuation of the second multivibrator to develop a third pulse which is applied to the welding electrodes.

3. A welding circuit according to claim 5 including means for independently adjusting the amplitude of each pulse developed by the multivibrator.

4. A welding circuit according to claim 1 including means for independently adjusting the width of each pulse developed by the multivibrators.

5. A resistance welding circuit comprising a pair of workpieces to be welded, a first direct current pulse generator for generating a first direct current pulse of a predetermined amplitude; first switching means operable in response to transmission of said first direct current pulse; a direct current source of electrical energy for supplying direct current to the workpieces; first attenuating circuit means including said first switching means interconnecting the source of energy and the workpieces; a second direct current pulse generator for generating a second direct current pulse having an amplitude greater than the amplitude of said first pulse; second switching means operable in response to transmission of said second direct current pulse and second attenuating circuit means including said second switching means interconnecting the source of energy and the workpieces.

6. Apparatus as claimed in claim 5 wherein said first and second direct current pulse generators are one shot multivibrators and said second one shot multivibrator is coupled to said first multivibrator to generate a pulse in response to termination of a pulse generated by said first multivibrator.

7. Apparatus as claimed in claim 6 comprising a third direct current pulse generator for generating a third direct current pulse having an amplitude less than the amplitude of said second pulse; third switching means operable in response to transmission of said third direct current pulse; and third attenuating circuit means including said third switching means interconnecting the source of energy and the workpieces.

8. Apparatus as claimed in claim 7, wherein said third direct current pulse generator is a third one shot multivibrator and said third one shot multivibrator is coupled to said second direct current pulse generator to generate a pulse in response to termination of a pulse generated by said second pulse generator.

9. Apparatus as claimed in claim 8, including a power amplifier for adjusting the power in the first, second and third, energy pulses from the energy source.

10. A method for the resistance spot welding of workpieces comprising the steps of generating a first direct current pulse of a predetermined duration, transmitting said first direct current pulse to a first switching means for closing a first attenuating circiut between a direct current source of electrical energy and the workpieces, maintaining closure of said first switching means for a predetermined amount of time to deliver a direct current preheating pulse of energy of a predetermined amplitude and duration from the energy source to the work electrodes, generating a second direct current pulse of a predetermined duration in response to the termination of the first direct current pulse, transmitting said second direct current pulse to a second switching means for closing a second attenuating circuit between the source of energy and the workpieces to be welded and maintaining closure of said second switching means for a predetermined amount of time to deliver a direct current welding pulse of energy having an amplitude greater than the amplitude of the preheating pulse from the energy source to the workpieces to be Welded.

11. A method as claimed in claim 13 including the steps of generating a third direct current pulse of predetermined duration in response to the termination of the second direct current pulse, transmitting said third direct current pulse to a third switching means for closing a third attenuating circuit between the source of energy and the workpieces and maintaining closure of said third switching means for a predetermined amount of time to deliver a direct current post-heating pulse of energy having an amplitude less than the amplitude of the welding pulse from the energy source to the workpieces to be welded.

References Cited UNITED STATES PATENTS 2,903,608 9/1959 Neidhardt 328- X 2,933,625 4/1960 Townsend et al.

3,178,551 4/1965 Webb 219- X 3,205,378 9/1965 Kline 219-108 X 3,233,116 2/1966 Waltrous 2191 14 X 3,243,652 3/1966 Meyer et a1 219-108 X 3,258,697 6/ 1966 Guettel 219-114 X RICHARD M. WOOD, Primary Examiner. J. G. SMITH, Assistant Examiner.

UNITED STATES PATENT OFFICE CERTIFICATE OF*CORRECTION PatentNo. 3,408,473 October 29, 1968 John A. Gilbert It is certified that error appears in the abovekidentified patent and that said Letters Patent are hereby corrected as shown below:

Column 1, line 33, "stop" should read spot Column 5, line 15, claim reference numeral "5" should read l Column 6, line 28, claim reference numeral "13" should read l0 Signed and sealed this 3rd day of March 1970.

(SEAL) Attest:

Edward M. Fletcher, Jr. Attesting Officer Commissioner of Patents 

